Ergonomic risk factors in material handling for warehouse operations.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Faculty of Manufacturing Engineering
ERGONOMIC RISK FACTORS IN MATERIAL HANDLING
FOR WAREHOUSE OPERATIONS
Rosmiza binti Majid
Master of Manufacturing Engineering
(Manufacturing System Engineering)
2013
ERGONOMIC RISK FACTORS IN MATERIAL HANDLING FOR WAREHOUSE
OPERATIONS
ROSMIZA BINTI MAJID
A thesis submitted
in fulfillment of the requirements for the degree of Master of Manufacturing
Engineering (Manufacturing System Engineering)
Faculty of Manufacturing Engineering
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
2013
DECLARATION
I declare that this thesis entitle "Ergonomic Risk Factors In Material Handling For
Warehouse Operations" is the result of my own reaesrch except as cited in the references.
The thesis has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.
Signature
Name
Date
ﾷｾＺ＠
..ｾ＠ ...... ｾ＠
... ｾＡＮＧＺｊ＠
...........
..ｾｉｄ＠
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial
fulfillment of the requirements for the degree of Master of Manufacturing (Manufacturing
System Engineering). The member of supervisory committee is as follow:
/
ｾ＠
/
----------------------------------------PROF. DR. ADI SAPTARI
ii
DEDICATION
To my beloved husband, daughters and son, thank you for your support and encouragement
To my mother and father, thank you for your 'Doa'
Ill
ABSTRACT
This project is conducted in Petronas Chemical Fertilizer Kedah Bhd. (PCFK)
which is a Malaysian urea production company and a wholly owned subsidiary of
Petroliam Nasional (Petronas). There are many risks for workers while performing the
jobs. One of them is ergonomic risk. This will have an affect to the safety of their
employees and in a long run will give impact to them. Eventually this risk will affect to the
productivity of workers.
The study on ergonomic risk factor assessment in manual
material handling being carried out at their material warehouse department. This study
aims to observe the current warehouse manual material handling activities and analyzing
the risk factors by computing the Composite Lifting Index (CLI) developed by NIOSH
(National Institute of Safety and Health) to identify tasks which pose to ergonomic risk.
The study identified lifting activities in the warehouse area. The activities of lifting and
lowering fast moving item, heavy items (stud bolt) and extreamly heavy item (Cage) was
analyzed using NIOSH Lifting Equations, and the CLI were computed. The results
indicates that there are significant level of physical stress associated with the selected tasks.
The study proposed the countermeasure include restructuring or changing workplace
conditions, to make the job easier, and reducing stressors that cause musculoskeletal
disorders. Redesigning the material handling activities can lead to a reduced CLI and thus
can also reduce the workers musculoskeletal discomfort situations. The proposed counter
measured was reevaluated to make sure that the jobs are safe according to NIOSH
standard.
iv
ABSTRAK
Projek ini dijalankan di Petronas Chemical Fertilizer Bhd. (PCFK) yang
merupakan sebuah syarikat pengeluar urea dan merifadi milik penuh Petroliam Nasional
(Petronas). Pekerja-pekerja sering terdedah dengan pelbagai risiko ketika melaksanakan
tugas mereka. Sa/ah satu daripadanya adalah risiko ergonomik. Jni akan memberi kesan
terhadap pekerja-pekerja dalam jangka masa panjang. Akhirnya, risiko ini akan memberi
kesan kepada produktiviti mereka. Kajian terhadap faktor risiko ergonomik terhadap
aktiviti pengurusan bahan secara manual ini telah dijalankan di dalam bahagian
penyimpanan bahan dan a/at ganti. Kajian ini bertujuan untuk membuat pemerhatian
terhadap aktiviti sedia ada di lokasi tersebut dan menganalisa risiko dengan mengira
Composite Lifting Index (CLI) yang dibangunkan oleh NIOSH (National Institute of Safety
and Health) bagi mengenalpasti aktiviti yang terdedah kepada risiko ergonomik. Kajian ini
telah mengenalpasti aktiviti mengangkat barangan di dalam kawasan lokasi yang
dimaksudkan. Aktiviti mengangkat dan menurunkan item-item yang sering digunakan,
item-item yang berat dan terlalu berat telah dinalisa menggunakan NIOSH Lifting
Equation dan nilai CL! telah diperolehi. Hasil yang diperolehi menunjukkan wujudnya
risiko ergonomik pada aktiviti tersebut. Kajian ini seterusnya mencadangkan beberapa
tindakan pembetulan termasuk penyusunan semula kawasan kerja, memudahkan aktiviti
kerja dan mengurangkan tekanan yang menyebabkan gangguan MSD. Rekebentuk semula
aktiviti pengurusan bahan ini akan menyumbangkan kepada pengurangan di dalam nilai
CL! dan seterusnya mengurangkan risiko MSD terdahap pekerja-pekerja.
v
ACKNOWLEDGEMENT
In preparing this thesis, lots of people have contributed towards my understanding and
thought. In particular, I wish to express my sincere appreciation and thanks to my thesis
supervisor, Professor Dr. Adi Saptari, for guidance, advices, encouragement, and
motivational support. Without his continued support and interest, this thesis would not
have been same as presented here.
I am also very thankful to Petronas Chemical Fertilizer's staffs, especially in Material
Warehouse Department for their cooperation and they deserve special thanks for their
assistance in supplying the relevant information and providing the required information.
I am grateful with my family. Husband who sacrifies a lot in helping me through all this
moment, daughters and son who always understand my time constraint and lovely mother
who always pray for my success.
My fellow postgraduate students should also be recognised for their support. My sincere
appreciation also extends to all my colleagues and others who have provided assistance at
various occasions. Their views and tips are useful indeed. Unfortunately, it is not possible
to list all of them in this limited space. I can only write here, 'Thank You' to all.
vi
LIST OF TABLES
TITLE
TABLE
PAGE
2.1
Successful Performance Approaches
10
3.1
Horizontal Multiplier (HM) factors
27
4.1
Survey's Participants Age Group
29
4.2
Working Conditions That Mostly Contribute to Ergonomic Risk
30
in PCFK's Warehouse
4.3
Frequency of pain occurred for specified body parts
32
4.4
NIOSH Lifting Variables for Task 1
36
4.5
Single Task Calculation Result for Task 1
39
4.6
Single Task Calculation Result for Task 1 (Renumbered)
40
4.7
NIOSH Lifting Variables for Task 2
43
4.8
Single Task Calculation Result for Task 2
44
4.9
Single Task Calculation Result for Task 2 (Renumbered)
45
4.10
NIOSH Lifting Variables for Task 3
49
4.11
Single Task Calculation Result for Task 3
49
4.12
Single Task Calculation Result for Task 3 (Renumbered)
50
Vll
LIST OF FIGURES
TITLE
FIGURE
PAGE
3.1
Flow chart of the methodology for risk factor assessment
20
3.2
Variable for Revised NIOSH Lifting Equations
24
4.1
Number of Survey Participants and Working Experience
29
4.2
Working Conditions That Mostly Contribute to Ergonomic Risk
31
in PCFK's Warehouse
4.3
Frequency of pain occurred for specified body parts
33
4.4
Store man performing task l
35
4.5
Store man performing task 2
42
4.6
Recently used trolley at studied Warehouse
46
4.7
Various types of manual lifting table trolley
47
4.8
Store man performing task 3
48
4.9
Mechanical Equipment to deal with heavy load
52
viii
LIST OF ABBREVIATIONS
PCFK
Petronas Chemical Fertilizer Kedah
MPI
Master Project 1
MP2
Master Project 2
OSHA
Occupational Safety and Health Administration
MSD
Musculoskeletal Disorder
LI
Lifting Index
RWL
Recommended Weight Limit
FIRWL
Frequency Independent Recommended Weight Limit
FILI
Frequency Independent Lifting Index
CLI
Composite Lifting Index
ix
LIST OF APPENDICES
PAGE
TITLE
APPENDIX
A
Task Analysis Form (Interview Form)
61
Bl
Questionnaire form Part 1 : Personnel Particulars
62
B2
Questionnaire form Part I : Workstation analysis
63
B3
Questionnaire form Part 3: Standardize Nordic Questionnaire For 65
Analysis Of Musculoskeletal Symptoms
C3
Job Analysis Worksheet
66
Dl
NIOSH Lifting Equation Analysis Calculation Data (Taskl)
67
(Single Task)
D2
NIOSH Lifting Equation Analysis Calculation Data (Taskl)
68
(Multi Task)
El
NIOSH Lifting Equation Analysis Re-Calculation Data (Task I)
69
(Single Task)
E2
NIOSH Lifting Equation Analysis Re-Calculation Data (Taskl)
70
(Multi Task)
Fl
NIOSH Lifting Equation Analysis Calculation Data (Task2)
71
(Single Task)
F2
NIOSH Lifting Equation Analysis Calculation Data (Task2)
(Multi Task)
x
72
Gl
NIOSH Lifting Equation Analysis Re-Calculation Data (Task2) . 73
(Single Task)
G2
NIOSH Lifting Equation Analysis Re-Calculation Data (Task2)
74
(Multi Task)
HI
NIOSH Lifting Equation Analysis Calculation Data (Task3)
75
(Single Task)
H2
NIOSH Lifting Equation Analysis Calculation Data (Task3)
(Multi Task)
xi
76
TABLE OF CONTENT
PAGE
DECLARATION
i
APPROVAL
ii
DEDICATION
iii
ABSTRACT
iv
ABSTRAK
v
ACKNOWLEDGEMENT
vi
LIST OFTABLES
vii
LIST OF FIGURES
viii
LIST OFABBREVIATIONS
ix
LIST OF APPENDICES
x
CHAPTER
1.
INTRODUCTION
1
I.I
Background
1
1.2
Statement of Purpose
2
1.3
Problem Statement
3
1.4
Objective of Study
3
1.5
Scope of Study
4
1.6
Importance of Study
4
1.7 Assumption
4
XII
1.8
2.
LITERATURE REVIEW
7
2.1
7
Introduction
2.2 Ergonomic and Productivity
8
2.3 Occupational Safety and Health Act (OSHA)
10
2.4 Biomechanics of Work
12
2.5 Manual Material Handling (MMH)
12
2.5.l
3.
5
Outline of Study Report
13
Force
2.5.2 Awkward Position
13
2.5.3 Frequency
15
2.5.4 Static Position
15
2.5.5 Lack of Recovery
16
2.5.6 Contact Stress
16
2.6 Ergonomic Risk Assessment
17
METHODOLOGY
19
3.1
19
Introduction
3.2 Flow Chart
21
3.3 Subject Selection and Description
21
3.4 Data Collection Procedure
21
3.4.l
21
Interview
3.4.2 Nordic Survey
22
3.4.3 Observation
23
3.5 Data Analysis
24
xiii
3.5.1
4.
25
NIOSH Lifting Equation
3 .6
Recommendation
26
3.7
Limittation
26
RESULT AND DISCUSSION
27
4.1
Introduction
28
4.2
Survey Analysis
21
4.2.1
Part 1: Personnel Information and knowledge on MSD
28
4.2.2
Part 2: Condition that mostly contribute to the ergonomic 29
Risk
4.2.3
4.3
Part 3: Symptoms of Musculoskeletal among workers
Case Study On Manual Material Handling
31
34
(Lifting And Lowering)
4.3.1
Case study I :
34
Manual handling of fast moving item during
issuing to customers (High repetition)
4.3 .1.1
Brief description of this task
34
4.3.1.2
Step 1 : Measure and record task variables
35
4.3.1.3
Step 2: Perform single task evaluation
38
4.3.l.4
Step 3: Renumber Tasks
39
4.3.1.5
Step 4: Calculate Composite Lifting Index
40
(CLI)
4.3.1.6
Recommended Countermeasure for task 1
xiv
41
4.3.2
42
Case study 2 :
Manual handling of fast moving item during
issuing to customers (High repetition)
4.3.2.1
Brief description of this task
42
4.3.2.2
Step 1 : Measure and record task variables
43
4.3.2.3
Step 2 : Perform single task evaluation
43
4.3.2.4
Step 3 : Renumber Tasks
44
4.3.2.5
Step 4 : Calculate Composite Lifting Index
45
(CL!)
4.3.2.6
4.3.3
Recommended Countermeasure for task 2
46
4
Case study 3 :
Manual handling of "Cage" during
issuing of goods to warehouse customers
4.3.3.1
Brief description of this task
48
4.3.3.2
Step 1 : Measure and record task variables
48
4.3.3.3
Step 2 : Perform single task evaluation
49
4.3.3.4
Step 3 : Renumber Tasks
50
4.3.3.5
Step 4 : Calculate Composite Lifting Index
50
(CLI)
4.3.3.6
Recommended Countermeasure for task 2
xv
51
5.
CONCLUSION
53
5.1
Conclusion
53
5.2
Survey Analysis
53
5.3
Observation of Ergonomic Risk Factors for selected Task
54
5.4
Other recommended countermeasure
55
5.4.1
Engineering Controls
55
5.4.2
Administrative Controls
56
3.4.3
Personnel Protective Equipment (PPE)
57
REFERENCE/BIBLIOGRAPHY
58
APPENDICES
61
xvi
CHAPTERl
INTRODUCTION
1.1
Background
Ergonomics is the science of fitting workplace conditions and job demands to the
capabilities of the working population (Occupational Safety and Health Administration,
Ergonomics, 2010). Other terms describe the ergonomics as the scientific study of the way
humans work. In ergonomics, a worker's capabilities are taken into account in direct
relation to the tasks required of him or her. Overall, ergonomics adapts the work to fit the
worker, instead of forcing the worker to adapt to the work. To ensure the protection to
human body, the ergonomic concept should be really focused. This kind of hazards occurs
in many ways and involves most of the field of works, types of tasks as well as working
area. One of the tasks that give impact to body structure and often being ignored by most
of the people is manual handling or manual material handling. Lifting and handling of
loads including lifting, lowering, pushing, pulling, carrying, holding, dragging and
supporting objects are also known as manual material handling. The injuries caused by
such work are referred to as musculoskeletal injuries, or MSis. Many studies have been
made to better understand 'manual material handling' activities and the particular risk
characteristics related to this type of work environment. It is well known that manual
materials handling is a hazardous activity, particularly for the low back (Troup et al., 1988;
Kumar, 1994; M. St-Vincent et al., 2005). According to Occupational Safety and Health
1
1.3
Problem Statement
There are many features of manual materials handling work affected a workers risk
of injury or Musculoskeletal Disorder (MSD) when they performed their task. Manual
material handling involves the awkward body posture, the repetitive motion or movement
and stress in body structure whether to reach for higher level position or material as well as
to lift high amount of load. This ergonomic risk that occurs due to improper technique of
performing task will affect the workers in many ways such as unhealthy condition, pain,
fatigue, discomfort situation and can lead to discourage from performing their job
efficiently. From company perspective, the problem occurs due to the effect of ergonomic
risk factors is increasing in absenteeism, high compensation claim, decrease in productivity
and can lead to losses in profit. Since the impact implicate both parties, workers and
employer, as well as influences the productivity, so it is a need to identify the root cause
and the consequences of the action. Realizing that this is a huge problem and the needs for
solution, inspire the writer decided to do a research that focuses on the analyzing several
activities in manual material handling including the causes and the consequences.
1.4
Objective of the study
There are several objectives that must be achieved in this study:
i.
To identify the occupational risk factor in manual material handling activities at
warehouse of Petronas Chemical Fertilizer Kedah (PCFK)
ii.
To analyze risk factor of the identified task in the PCFK's material warehouse.
iii.
To recommend appropriate countermeasure to reduce the occurrence of
identified ergonomic risk
3
1.5
Scope of the study
In order of achieving the objectives stated above, there are few importance elements
to be considered during the study. The scope of the study only cover the manual material
handling in warehouse activities and no considerations are being be made for handling
techniques outside the defined study area. This study is only for the purpose of identifying
the problem occurs during the current handling technique in PCFK. The conclusion that is
provided at the end of the report is based on what has been study according to the
observation and questionnaire among the selected workers and will not reflect the whole
activities in PCFK.
Importance of the study
1.6
This study seem to be significance since the ergonomic risk due few factors such
as:•
Ergonomic risk will affected the employee's safety and in long run will give bad
impact to them. Eventually, this will influence their productivity and affected the
employer.
•
Employees are necessary to perform the job and are vital in representing and
protecting a companies' performance. Therefore they should be taken care off.
•
Ergonomics can help company to protect this asset by increasing morale,
productivity and work quality, and also reducing turnover and absenteeism and
workers' compensation claim
1.7
Assumptions
i.
The involvement of the workers from selected field in study may be limited and
this will affected the final results.
4
ii.
The workers tend to focus on completing their task in a short period rather than
give attention to the ergonomics factors.
iii.
The readiness of the workers to perform their task with the same technique as
they would do during a non-observed day will also give impact to the finding of
this study
IV.
The employee's might be hardly altering their normal work practice or habit to
adhere to the suggested technique in the end of study.
1.8
Outlines of the Study Report
This study comprises of overall six chapters. First chapter is for introduction
purpose. The content of this chapter is about an overview of the study and then proceeds
with statement of purpose, problem statement and objectives, scope and the importance of
the study. Finally in this first chapter will also include the assumption made during this
study.
The literature review in chapter II will review on few journals and reading materials on
manual material handling. The elements that are going to be focused is the manual material
handling principle, background related to the study, tools and techniques for manual
material handling, method of analysing the manual material handling effect and effects of
the manual material handling activities. Finally, this chapter will conclude the elements to
be considered in the methodology of this study.
Chapter III is the research methodology section. This chapter will explain the methodology
that will be used to collect the information and gather it to support types of software that
has been used to analysis of the study. This is the vital stage where the full procedure of
this study is planned.
5
The following chapter are results and discussion. In chapter IV, the data collected by the
method discussed in chapter III are being analysed using NIOSH Lifting Equation.
Recommendations countermeasure are discussed in this chapter.
In Chapter V, the conclusion is made with regards to all the result in chapter IV. In this
chapter, the achievements of all the stated objectives are discussed. This chapter also
provide more recommendations to reduce any risk factors that may be contributing to the
discomfort and also the suggestions to the workers and their employers so that safe
working environment will be generated. This situation will prevent hazards in performing
their task. The recommendations are basically regarding the result of the analysis using
ergonomic concept.
6
CHAPTER2
LITERATURE REVIEW
2.1
Introduction
The purpose of this study was to analyze the current methods in manual material
handling in warehouse activities. The objectives were to observe the practices that the
employees follow as it relates to the transfer of materials form the place it is received from
transporter to the storage area in the company's warehouse. This includes the activities of
arranging the goods in the allocated places or rack. The employees give less consideration
towards their posture in performing those activities. Without knowing that their deeds are
propping up hazard and sometimes caused the injury, they put more concern on completing
their task. With the awareness of these injury will lead to the absenteeism of the
employees, or the repetitive small injury (without any concern or action from top
management) will affect the morale of the employees, many companies have realized that
this matter had become a major concern and should be given full attention. Moreover,
every ringgit spent on a worker compensation claim is an amount that directly out of the
company profits. By identifying hazardous or high risk work activities and working to
modify the work activities to reduce or eliminate the risk, a company can lower the
potential for injuries in the workplace. The review of the literature will support that injury
to the employees while handling the materials by hand is a major concern for the company.
7
Faculty of Manufacturing Engineering
ERGONOMIC RISK FACTORS IN MATERIAL HANDLING
FOR WAREHOUSE OPERATIONS
Rosmiza binti Majid
Master of Manufacturing Engineering
(Manufacturing System Engineering)
2013
ERGONOMIC RISK FACTORS IN MATERIAL HANDLING FOR WAREHOUSE
OPERATIONS
ROSMIZA BINTI MAJID
A thesis submitted
in fulfillment of the requirements for the degree of Master of Manufacturing
Engineering (Manufacturing System Engineering)
Faculty of Manufacturing Engineering
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
2013
DECLARATION
I declare that this thesis entitle "Ergonomic Risk Factors In Material Handling For
Warehouse Operations" is the result of my own reaesrch except as cited in the references.
The thesis has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.
Signature
Name
Date
ﾷｾＺ＠
..ｾ＠ ...... ｾ＠
... ｾＡＮＧＺｊ＠
...........
..ｾｉｄ＠
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial
fulfillment of the requirements for the degree of Master of Manufacturing (Manufacturing
System Engineering). The member of supervisory committee is as follow:
/
ｾ＠
/
----------------------------------------PROF. DR. ADI SAPTARI
ii
DEDICATION
To my beloved husband, daughters and son, thank you for your support and encouragement
To my mother and father, thank you for your 'Doa'
Ill
ABSTRACT
This project is conducted in Petronas Chemical Fertilizer Kedah Bhd. (PCFK)
which is a Malaysian urea production company and a wholly owned subsidiary of
Petroliam Nasional (Petronas). There are many risks for workers while performing the
jobs. One of them is ergonomic risk. This will have an affect to the safety of their
employees and in a long run will give impact to them. Eventually this risk will affect to the
productivity of workers.
The study on ergonomic risk factor assessment in manual
material handling being carried out at their material warehouse department. This study
aims to observe the current warehouse manual material handling activities and analyzing
the risk factors by computing the Composite Lifting Index (CLI) developed by NIOSH
(National Institute of Safety and Health) to identify tasks which pose to ergonomic risk.
The study identified lifting activities in the warehouse area. The activities of lifting and
lowering fast moving item, heavy items (stud bolt) and extreamly heavy item (Cage) was
analyzed using NIOSH Lifting Equations, and the CLI were computed. The results
indicates that there are significant level of physical stress associated with the selected tasks.
The study proposed the countermeasure include restructuring or changing workplace
conditions, to make the job easier, and reducing stressors that cause musculoskeletal
disorders. Redesigning the material handling activities can lead to a reduced CLI and thus
can also reduce the workers musculoskeletal discomfort situations. The proposed counter
measured was reevaluated to make sure that the jobs are safe according to NIOSH
standard.
iv
ABSTRAK
Projek ini dijalankan di Petronas Chemical Fertilizer Bhd. (PCFK) yang
merupakan sebuah syarikat pengeluar urea dan merifadi milik penuh Petroliam Nasional
(Petronas). Pekerja-pekerja sering terdedah dengan pelbagai risiko ketika melaksanakan
tugas mereka. Sa/ah satu daripadanya adalah risiko ergonomik. Jni akan memberi kesan
terhadap pekerja-pekerja dalam jangka masa panjang. Akhirnya, risiko ini akan memberi
kesan kepada produktiviti mereka. Kajian terhadap faktor risiko ergonomik terhadap
aktiviti pengurusan bahan secara manual ini telah dijalankan di dalam bahagian
penyimpanan bahan dan a/at ganti. Kajian ini bertujuan untuk membuat pemerhatian
terhadap aktiviti sedia ada di lokasi tersebut dan menganalisa risiko dengan mengira
Composite Lifting Index (CLI) yang dibangunkan oleh NIOSH (National Institute of Safety
and Health) bagi mengenalpasti aktiviti yang terdedah kepada risiko ergonomik. Kajian ini
telah mengenalpasti aktiviti mengangkat barangan di dalam kawasan lokasi yang
dimaksudkan. Aktiviti mengangkat dan menurunkan item-item yang sering digunakan,
item-item yang berat dan terlalu berat telah dinalisa menggunakan NIOSH Lifting
Equation dan nilai CL! telah diperolehi. Hasil yang diperolehi menunjukkan wujudnya
risiko ergonomik pada aktiviti tersebut. Kajian ini seterusnya mencadangkan beberapa
tindakan pembetulan termasuk penyusunan semula kawasan kerja, memudahkan aktiviti
kerja dan mengurangkan tekanan yang menyebabkan gangguan MSD. Rekebentuk semula
aktiviti pengurusan bahan ini akan menyumbangkan kepada pengurangan di dalam nilai
CL! dan seterusnya mengurangkan risiko MSD terdahap pekerja-pekerja.
v
ACKNOWLEDGEMENT
In preparing this thesis, lots of people have contributed towards my understanding and
thought. In particular, I wish to express my sincere appreciation and thanks to my thesis
supervisor, Professor Dr. Adi Saptari, for guidance, advices, encouragement, and
motivational support. Without his continued support and interest, this thesis would not
have been same as presented here.
I am also very thankful to Petronas Chemical Fertilizer's staffs, especially in Material
Warehouse Department for their cooperation and they deserve special thanks for their
assistance in supplying the relevant information and providing the required information.
I am grateful with my family. Husband who sacrifies a lot in helping me through all this
moment, daughters and son who always understand my time constraint and lovely mother
who always pray for my success.
My fellow postgraduate students should also be recognised for their support. My sincere
appreciation also extends to all my colleagues and others who have provided assistance at
various occasions. Their views and tips are useful indeed. Unfortunately, it is not possible
to list all of them in this limited space. I can only write here, 'Thank You' to all.
vi
LIST OF TABLES
TITLE
TABLE
PAGE
2.1
Successful Performance Approaches
10
3.1
Horizontal Multiplier (HM) factors
27
4.1
Survey's Participants Age Group
29
4.2
Working Conditions That Mostly Contribute to Ergonomic Risk
30
in PCFK's Warehouse
4.3
Frequency of pain occurred for specified body parts
32
4.4
NIOSH Lifting Variables for Task 1
36
4.5
Single Task Calculation Result for Task 1
39
4.6
Single Task Calculation Result for Task 1 (Renumbered)
40
4.7
NIOSH Lifting Variables for Task 2
43
4.8
Single Task Calculation Result for Task 2
44
4.9
Single Task Calculation Result for Task 2 (Renumbered)
45
4.10
NIOSH Lifting Variables for Task 3
49
4.11
Single Task Calculation Result for Task 3
49
4.12
Single Task Calculation Result for Task 3 (Renumbered)
50
Vll
LIST OF FIGURES
TITLE
FIGURE
PAGE
3.1
Flow chart of the methodology for risk factor assessment
20
3.2
Variable for Revised NIOSH Lifting Equations
24
4.1
Number of Survey Participants and Working Experience
29
4.2
Working Conditions That Mostly Contribute to Ergonomic Risk
31
in PCFK's Warehouse
4.3
Frequency of pain occurred for specified body parts
33
4.4
Store man performing task l
35
4.5
Store man performing task 2
42
4.6
Recently used trolley at studied Warehouse
46
4.7
Various types of manual lifting table trolley
47
4.8
Store man performing task 3
48
4.9
Mechanical Equipment to deal with heavy load
52
viii
LIST OF ABBREVIATIONS
PCFK
Petronas Chemical Fertilizer Kedah
MPI
Master Project 1
MP2
Master Project 2
OSHA
Occupational Safety and Health Administration
MSD
Musculoskeletal Disorder
LI
Lifting Index
RWL
Recommended Weight Limit
FIRWL
Frequency Independent Recommended Weight Limit
FILI
Frequency Independent Lifting Index
CLI
Composite Lifting Index
ix
LIST OF APPENDICES
PAGE
TITLE
APPENDIX
A
Task Analysis Form (Interview Form)
61
Bl
Questionnaire form Part 1 : Personnel Particulars
62
B2
Questionnaire form Part I : Workstation analysis
63
B3
Questionnaire form Part 3: Standardize Nordic Questionnaire For 65
Analysis Of Musculoskeletal Symptoms
C3
Job Analysis Worksheet
66
Dl
NIOSH Lifting Equation Analysis Calculation Data (Taskl)
67
(Single Task)
D2
NIOSH Lifting Equation Analysis Calculation Data (Taskl)
68
(Multi Task)
El
NIOSH Lifting Equation Analysis Re-Calculation Data (Task I)
69
(Single Task)
E2
NIOSH Lifting Equation Analysis Re-Calculation Data (Taskl)
70
(Multi Task)
Fl
NIOSH Lifting Equation Analysis Calculation Data (Task2)
71
(Single Task)
F2
NIOSH Lifting Equation Analysis Calculation Data (Task2)
(Multi Task)
x
72
Gl
NIOSH Lifting Equation Analysis Re-Calculation Data (Task2) . 73
(Single Task)
G2
NIOSH Lifting Equation Analysis Re-Calculation Data (Task2)
74
(Multi Task)
HI
NIOSH Lifting Equation Analysis Calculation Data (Task3)
75
(Single Task)
H2
NIOSH Lifting Equation Analysis Calculation Data (Task3)
(Multi Task)
xi
76
TABLE OF CONTENT
PAGE
DECLARATION
i
APPROVAL
ii
DEDICATION
iii
ABSTRACT
iv
ABSTRAK
v
ACKNOWLEDGEMENT
vi
LIST OFTABLES
vii
LIST OF FIGURES
viii
LIST OFABBREVIATIONS
ix
LIST OF APPENDICES
x
CHAPTER
1.
INTRODUCTION
1
I.I
Background
1
1.2
Statement of Purpose
2
1.3
Problem Statement
3
1.4
Objective of Study
3
1.5
Scope of Study
4
1.6
Importance of Study
4
1.7 Assumption
4
XII
1.8
2.
LITERATURE REVIEW
7
2.1
7
Introduction
2.2 Ergonomic and Productivity
8
2.3 Occupational Safety and Health Act (OSHA)
10
2.4 Biomechanics of Work
12
2.5 Manual Material Handling (MMH)
12
2.5.l
3.
5
Outline of Study Report
13
Force
2.5.2 Awkward Position
13
2.5.3 Frequency
15
2.5.4 Static Position
15
2.5.5 Lack of Recovery
16
2.5.6 Contact Stress
16
2.6 Ergonomic Risk Assessment
17
METHODOLOGY
19
3.1
19
Introduction
3.2 Flow Chart
21
3.3 Subject Selection and Description
21
3.4 Data Collection Procedure
21
3.4.l
21
Interview
3.4.2 Nordic Survey
22
3.4.3 Observation
23
3.5 Data Analysis
24
xiii
3.5.1
4.
25
NIOSH Lifting Equation
3 .6
Recommendation
26
3.7
Limittation
26
RESULT AND DISCUSSION
27
4.1
Introduction
28
4.2
Survey Analysis
21
4.2.1
Part 1: Personnel Information and knowledge on MSD
28
4.2.2
Part 2: Condition that mostly contribute to the ergonomic 29
Risk
4.2.3
4.3
Part 3: Symptoms of Musculoskeletal among workers
Case Study On Manual Material Handling
31
34
(Lifting And Lowering)
4.3.1
Case study I :
34
Manual handling of fast moving item during
issuing to customers (High repetition)
4.3 .1.1
Brief description of this task
34
4.3.1.2
Step 1 : Measure and record task variables
35
4.3.1.3
Step 2: Perform single task evaluation
38
4.3.l.4
Step 3: Renumber Tasks
39
4.3.1.5
Step 4: Calculate Composite Lifting Index
40
(CLI)
4.3.1.6
Recommended Countermeasure for task 1
xiv
41
4.3.2
42
Case study 2 :
Manual handling of fast moving item during
issuing to customers (High repetition)
4.3.2.1
Brief description of this task
42
4.3.2.2
Step 1 : Measure and record task variables
43
4.3.2.3
Step 2 : Perform single task evaluation
43
4.3.2.4
Step 3 : Renumber Tasks
44
4.3.2.5
Step 4 : Calculate Composite Lifting Index
45
(CL!)
4.3.2.6
4.3.3
Recommended Countermeasure for task 2
46
4
Case study 3 :
Manual handling of "Cage" during
issuing of goods to warehouse customers
4.3.3.1
Brief description of this task
48
4.3.3.2
Step 1 : Measure and record task variables
48
4.3.3.3
Step 2 : Perform single task evaluation
49
4.3.3.4
Step 3 : Renumber Tasks
50
4.3.3.5
Step 4 : Calculate Composite Lifting Index
50
(CLI)
4.3.3.6
Recommended Countermeasure for task 2
xv
51
5.
CONCLUSION
53
5.1
Conclusion
53
5.2
Survey Analysis
53
5.3
Observation of Ergonomic Risk Factors for selected Task
54
5.4
Other recommended countermeasure
55
5.4.1
Engineering Controls
55
5.4.2
Administrative Controls
56
3.4.3
Personnel Protective Equipment (PPE)
57
REFERENCE/BIBLIOGRAPHY
58
APPENDICES
61
xvi
CHAPTERl
INTRODUCTION
1.1
Background
Ergonomics is the science of fitting workplace conditions and job demands to the
capabilities of the working population (Occupational Safety and Health Administration,
Ergonomics, 2010). Other terms describe the ergonomics as the scientific study of the way
humans work. In ergonomics, a worker's capabilities are taken into account in direct
relation to the tasks required of him or her. Overall, ergonomics adapts the work to fit the
worker, instead of forcing the worker to adapt to the work. To ensure the protection to
human body, the ergonomic concept should be really focused. This kind of hazards occurs
in many ways and involves most of the field of works, types of tasks as well as working
area. One of the tasks that give impact to body structure and often being ignored by most
of the people is manual handling or manual material handling. Lifting and handling of
loads including lifting, lowering, pushing, pulling, carrying, holding, dragging and
supporting objects are also known as manual material handling. The injuries caused by
such work are referred to as musculoskeletal injuries, or MSis. Many studies have been
made to better understand 'manual material handling' activities and the particular risk
characteristics related to this type of work environment. It is well known that manual
materials handling is a hazardous activity, particularly for the low back (Troup et al., 1988;
Kumar, 1994; M. St-Vincent et al., 2005). According to Occupational Safety and Health
1
1.3
Problem Statement
There are many features of manual materials handling work affected a workers risk
of injury or Musculoskeletal Disorder (MSD) when they performed their task. Manual
material handling involves the awkward body posture, the repetitive motion or movement
and stress in body structure whether to reach for higher level position or material as well as
to lift high amount of load. This ergonomic risk that occurs due to improper technique of
performing task will affect the workers in many ways such as unhealthy condition, pain,
fatigue, discomfort situation and can lead to discourage from performing their job
efficiently. From company perspective, the problem occurs due to the effect of ergonomic
risk factors is increasing in absenteeism, high compensation claim, decrease in productivity
and can lead to losses in profit. Since the impact implicate both parties, workers and
employer, as well as influences the productivity, so it is a need to identify the root cause
and the consequences of the action. Realizing that this is a huge problem and the needs for
solution, inspire the writer decided to do a research that focuses on the analyzing several
activities in manual material handling including the causes and the consequences.
1.4
Objective of the study
There are several objectives that must be achieved in this study:
i.
To identify the occupational risk factor in manual material handling activities at
warehouse of Petronas Chemical Fertilizer Kedah (PCFK)
ii.
To analyze risk factor of the identified task in the PCFK's material warehouse.
iii.
To recommend appropriate countermeasure to reduce the occurrence of
identified ergonomic risk
3
1.5
Scope of the study
In order of achieving the objectives stated above, there are few importance elements
to be considered during the study. The scope of the study only cover the manual material
handling in warehouse activities and no considerations are being be made for handling
techniques outside the defined study area. This study is only for the purpose of identifying
the problem occurs during the current handling technique in PCFK. The conclusion that is
provided at the end of the report is based on what has been study according to the
observation and questionnaire among the selected workers and will not reflect the whole
activities in PCFK.
Importance of the study
1.6
This study seem to be significance since the ergonomic risk due few factors such
as:•
Ergonomic risk will affected the employee's safety and in long run will give bad
impact to them. Eventually, this will influence their productivity and affected the
employer.
•
Employees are necessary to perform the job and are vital in representing and
protecting a companies' performance. Therefore they should be taken care off.
•
Ergonomics can help company to protect this asset by increasing morale,
productivity and work quality, and also reducing turnover and absenteeism and
workers' compensation claim
1.7
Assumptions
i.
The involvement of the workers from selected field in study may be limited and
this will affected the final results.
4
ii.
The workers tend to focus on completing their task in a short period rather than
give attention to the ergonomics factors.
iii.
The readiness of the workers to perform their task with the same technique as
they would do during a non-observed day will also give impact to the finding of
this study
IV.
The employee's might be hardly altering their normal work practice or habit to
adhere to the suggested technique in the end of study.
1.8
Outlines of the Study Report
This study comprises of overall six chapters. First chapter is for introduction
purpose. The content of this chapter is about an overview of the study and then proceeds
with statement of purpose, problem statement and objectives, scope and the importance of
the study. Finally in this first chapter will also include the assumption made during this
study.
The literature review in chapter II will review on few journals and reading materials on
manual material handling. The elements that are going to be focused is the manual material
handling principle, background related to the study, tools and techniques for manual
material handling, method of analysing the manual material handling effect and effects of
the manual material handling activities. Finally, this chapter will conclude the elements to
be considered in the methodology of this study.
Chapter III is the research methodology section. This chapter will explain the methodology
that will be used to collect the information and gather it to support types of software that
has been used to analysis of the study. This is the vital stage where the full procedure of
this study is planned.
5
The following chapter are results and discussion. In chapter IV, the data collected by the
method discussed in chapter III are being analysed using NIOSH Lifting Equation.
Recommendations countermeasure are discussed in this chapter.
In Chapter V, the conclusion is made with regards to all the result in chapter IV. In this
chapter, the achievements of all the stated objectives are discussed. This chapter also
provide more recommendations to reduce any risk factors that may be contributing to the
discomfort and also the suggestions to the workers and their employers so that safe
working environment will be generated. This situation will prevent hazards in performing
their task. The recommendations are basically regarding the result of the analysis using
ergonomic concept.
6
CHAPTER2
LITERATURE REVIEW
2.1
Introduction
The purpose of this study was to analyze the current methods in manual material
handling in warehouse activities. The objectives were to observe the practices that the
employees follow as it relates to the transfer of materials form the place it is received from
transporter to the storage area in the company's warehouse. This includes the activities of
arranging the goods in the allocated places or rack. The employees give less consideration
towards their posture in performing those activities. Without knowing that their deeds are
propping up hazard and sometimes caused the injury, they put more concern on completing
their task. With the awareness of these injury will lead to the absenteeism of the
employees, or the repetitive small injury (without any concern or action from top
management) will affect the morale of the employees, many companies have realized that
this matter had become a major concern and should be given full attention. Moreover,
every ringgit spent on a worker compensation claim is an amount that directly out of the
company profits. By identifying hazardous or high risk work activities and working to
modify the work activities to reduce or eliminate the risk, a company can lower the
potential for injuries in the workplace. The review of the literature will support that injury
to the employees while handling the materials by hand is a major concern for the company.
7